Radio frequency identification (RFID) sensor network for a work machine

ABSTRACT

An agricultural work machine, an agricultural work machine control system, and method for an agricultural work machine having RFID tags to determine a fault condition of machine components, devices, parts or systems. The RFID tags are located on, at, or near machine components or systems to sense a temperature of those components or systems. A receiver/transmitter interrogates the RFID tags and receives the sensed temperatures, and component identifiers. A controller receives the temperatures from the receiver/transmitter and compares the received temperatures to a threshold to determine whether a fault condition exists. If so, the controller transmits an alert signal to a user interface to indicate that a fault condition exists with an identified component, part, device, or system.

FIELD OF THE DISCLOSURE

The present disclosure relates to a work machine, and more particularlyto a method and apparatus to identify a fault condition of a componentof an agricultural work machine.

BACKGROUND

Work machines are configured to perform a wide variety of tasks for useas construction machines, forestry machines, lawn maintenance machines,as well as on-road machines such as those used to plow snow, spreadsalt, or machines with towing capability. Additionally, work machinesinclude agricultural machines, such as a tractor or a self-propelledcombine-harvester, which include a prime mover that generates power toperform work. In the case of a tractor, for instance, the prime mover isoften a diesel engine that generates power from a supply of diesel fuel.The diesel engine drives a transmission which moves wheels or treads topropel the tractor across a field at a designated speed. Tractors ofteninclude a power takeoff (PTO) which includes a shaft coupled to thetransmission and driven by the engine to power a machine being pulled orpushed through a field by the tractor. Other agricultural work machinesinclude machines pulled by a tractor, for instance, pull type combines,pull type harvesters, pull type balers, seeders, and spreaders. Workmachines are also known as work vehicles.

Tractors can be steered through a field by a manual command provided byan operator located in a cab through a manually controlled steeringdevice, such as a steering wheel or joystick, or by an automaticsteering command. In the case of an automatic steering command, asteering control signal can be provided by a global positioning system(GPS) signal. Steering control systems often include one or more sensorsconfigured to sense a position of the steering device or a position ofthe wheels with respect to a frame of the machine.

Harvesting machines, such as hay and foraging machines utilized in theprocessing of plant material can include mowers, conditioners, flailchoppers, windrowers, combines, forage harvesters, and balers for bothdry and silage uses. Such harvesting machines are often pulled by thetractor through a field. Self-propelled harvesting machinery is alsoknown.

Historically, tractors and harvesting machines have been driven by anoperator. One of the tasks the operator performed was to “listen” to themachine during operation to make sure there are no damaged or brokencomponents on the machine. In some work vehicles, however, a damaged orbroken component may not provide a sound that indicates a part isdamaged or broken, and may only be noticed by a work machine failing toproperly carry out an operation, i.e. a fault condition.

In some machines, temperature sensors are used to identify systems,parts, or devices, that are experiencing fault conditions. In somemachines, temperature sensing is done with stationary thermocouples inengines, oil baths, or air intakes, for example. These sensors areconnected by wire to a controller. Various sensors are also attached tomoving parts, for example a rotating shaft. Communication to aprocessing unit can occur via wire with a slip ring, or wirelessly witha powered (battery powered) beacon; which are expensive and requirefrequent maintenance.

Today's agricultural equipment is becoming more complex with higherexpectations for reliability. Predictive monitoring of equipment canreduce costly downtime, for example saving hay that needs to be baledwhen the rain clouds are rolling in. The cost of sensors for all of thepotential failure locations, the challenge of mounting them on movingparts, and connecting them to a processing unit, make it impractical andcost prohibitive to implement. In other circumstances, the fact that amachine is failing to work as intended, may not be noticeable as theremay not be warning signs to indicate that a part is failing or hasfailed. What is needed, therefore, is a system to identify a faultcondition in a machine part, device, or component, and in particular toidentify a fault condition before the part experiencing the faultcondition fails completely.

SUMMARY

In one embodiment, there is provided a method of detecting a faultcondition in one or more balers, each of which includes a crop feedsystem and a bale chamber, wherein each of the one or more balers isconfigured to bale cut crop. The method includes: identifying at leastone location in the one or more balers, wherein the at least oneidentified location generates heat during an operation of a component ofthe crop feed system or the bale chamber; placing a radio frequencyidentification (RFID) tag at the at least one identified location,wherein the RFID tag includes a temperature sensing feature; receivingtransmitted data from the RFID tag; identifying, from the received data,a temperature value of the at least one identified location; andproviding an indictor based on the identified temperature value.

In another embodiment, there is provided a system for identifying afault condition in one or more balers, each of which includes aplurality of components. The system includes one or more RFID tags,wherein each of the one or more RFID tags includes a temperature sensorand a coupler to connect each one of the one or more RFID tags to alocation at, near, or on one of the plurality of components. A receiveris configured to receive temperature information from each of the one ormore RFID tags. A controller is operatively connected to the receiverand to a user interface, wherein the controller includes a processor anda memory. The memory is configured to store program instructions and theprocessor is configured to execute the stored program instructions to:receive temperature information from the receiver; identify a faultcondition of one or more of the plurality of components based on thereceived temperature information; and display an indicator at the userinterface based on the identified fault condition.

In a further embodiment, there is provided a baler configured to balecut crop. The baler includes a crop feed system, a bale chamber, and oneor more RFID tags, each of which includes a temperature sensing feature.Each of the one or more RFID tags is located on, at, or near a componentof one the crop feed system, or the bale chamber. An RFID tag reader isconfigured to receive temperature information from the one or more RFIDtags. The baler further includes a user interface having one or moreindicators and a controller operatively connected to the user interfaceand to the RFID tag reader. The controller includes a processor and amemory. The memory is configured to store program instructions and theprocessor is configured to execute the stored program instructions to:receive the temperature information from the RFID tag reader; identify afault condition of one or more of the plurality of components based onthe received temperature information; and activate one of the one ormore indicators at the user interface based on the identified faultcondition.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned aspects of the present invention and the manner ofobtaining them will become more apparent and the invention itself willbe better understood by reference to the following description of theembodiments of the invention, taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of an example baler towed by anagricultural machine;

FIG. 2 is a perspective view of the baler of FIG. 1, with portions ofthe cover of the baler removed;

FIG. 3 is a schematic elevational side view of the baler of FIG. 2.

FIG. 4 is a schematic block diagram of a control system configured todetermine a fault condition of a component or system of a work machine;

FIG. 5 illustrates an RFID sensor coupled to a bearing;

FIG. 6 illustrates an RFID sensor coupled to a gearbox;

FIG. 7 illustrates components of the baler of FIG. 2;

FIG. 8 illustrates a network of RFID sensors; and

FIG. 9 illustrates an embodiment of a screen display.

DETAILED DESCRIPTION

The embodiments of the present disclosure described below are notintended to be exhaustive or to limit the disclosure to the preciseforms disclosed in the following detailed description. Rather, theembodiments are chosen and described so that others skilled in the artmay appreciate and understand the principles and practices of thepresent disclosure.

Referring now to FIG. 1, an agricultural machine 10, such as a tractor,is coupled to a round baler 20 which is towed across a field by theagricultural machine 10. (It will be understood that various otherconfigurations are also possible. For example, the disclosed systems andmethods may be utilized with a variety of balers or other harvestingmachines, either puled by a machine or a self-propelled machine.) Thetractor 10 includes a frame supported by wheels 21 which are driven byan engine, not shown, located in a housing 24, also supported by theframe. A cab 26 is supported by the frame and includes an operatorstation configured to enclose a user operating the tractor 10 with auser control console, as is understood by one skilled in the art. Anantenna 28 is located on the cab 26 and is configured to receive and totransmit wireless signals to and from an externally located source ofdata information, such as is available over the web through a cloudsystem, or to and from a global positioning system (GPS) 29 (See FIG. 4)which is configured to supply location information machine controlinformation to a tractor controller 30. In different embodiments, forinstance, the GPS system directs the machine 10 through the field alonga predetermined path to provide for planting, harvesting, plowing, andfertilizing. Other machine functions are contemplated.

The round baler 20 includes a housing 32. The housing 32 is attached toand supported by a frame 22 of the baler 20. The housing 32 may includeone or more walls or panels that at least partially enclose and/ordefine an interior region. The round baler 20 further includes a gate36. (See FIGS. 1 and 2.) The gate 36 may include one or more walls orpanels that at least partially enclose and/or define the interiorregion. As such, the housing 32 and the gate 36 cooperate to define theinterior region therebetween.

As baler 20 moves across a field (e.g., as towed by machine 10 viaconnection 33) and encounters a windrow or other arrangement of material(not shown), a pick-up assembly 48 (See FIG. 3) gathers the material andmoves it up and into baler 20 for processing. As a result of thisprocessing, as described in greater detail below, a round bale is formedand ejected from the gate 36 of baler 20. The connection 33 alsoincludes a power take-off, as is understood by one skilled in the art,and a gearbox (not shown) located within a housing 35.

As seen in FIGS. 2 and 3, the gate 36 is attached to and rotatablysupported by the housing 32. The gate 36 is positioned adjacent arearward end 38 of the frame 22 relative to a direction of travel 40 ofthe round baler 20 while gathering crop material, and is pivotablymoveable about a gate rotation axis 42. The gate rotation axis 42 isgenerally horizontal and perpendicular to a central longitudinal axis 44of the frame 22. The central longitudinal axis 44 of the round baler 20extends between the forward end 28 and the rearward end 38 of the roundbaler 20. The gate 36 is moveable between a closed position for forminga bale 56 within the interior region 34, and an open position fordischarging the bale 56 from the interior region 34 onto a groundsurface 46

The round baler 20 includes the pick-up 48 disposed proximate theforward end of the frame 22. The pick-up 48 gathers crop material fromthe ground surface 46 and directs the gathered crop material toward andinto an inlet 50 of the interior region 34. The pickup may include, butis not limited to tines, forks, augers, conveyors, baffles, etc., forgathering and moving the crop material. The round baler 20 may beequipped with a pre-cutter (not shown), disposed between the pickup andthe inlet 50. As such, the pre-cutter is disposed downstream of thepickup and upstream of the inlet 50 relative to movement of the cropmaterial. As is understood by those skilled in the art, the pre-cuttercuts or chops the crop material into smaller pieces.

A bale formation system 52 is disposed within the interior region 34 anddefines baling chamber 54, within which bale 56 is formed. The baleformation system 52 is operable to form the bale 56 to have acylindrical shape.

The bale formation system 52, in one embodiment, is configured as avariable chamber baler. Referring to FIGS. 2 and 3, and as is understoodby those skilled in the art, the variable chamber baler includes atleast one, and may include a plurality of longitudinally extendingside-by-side forming belts 64 that are supported by a plurality ofrollers 66. The forming belts 64 define the baling chamber 54 and movein an endless loop to form crop material into the bale 56. The bale 56is formed by the forming belts 64 and one or more side walls of thehousing 32 and gate 36. As is understood by those skilled in the art,the forming belts 64 are controlled to vary the diametric size of thebaling chamber 54.

The plurality of rollers 66 support the forming belts 64. At least oneof the rollers 66 is a take-up roller 68. The take-up roller 68 ismoveably coupled to one of the gate 36 or the housing 32, and isoperable or moveable to decrease slack in the forming belts 64 when thegate 36 of the round baler 20 is opened. Additionally, at least one ofthe plurality of rollers 66 may include a drive roller 70 that isoperable to drive the forming belts 64 in the endless loop throughfrictional engagement between the forming belts 64 and the drive roller70.

The crop material is directed through the inlet 50 and into the balingchamber 54, whereby the forming belts 64 roll the crop material in aspiral fashion into the bale 56 having the cylindrical shape. The beltsapply a constant pressure to the crop material as the crop material isformed into the bale 56. A belt tensioner 72 continuously moves one ormore of the rollers 66, and thereby the forming belts 64, radiallyoutward relative to the centerline 62 of the cylindrical bale 56 as adiameter of the bale 56 increases. The belt tensioner 72 maintains theappropriate tension in the belts to obtain the desired density of thecrop material.

As shown in FIG. 3, the round baler 20 may include a wrap system 74. Thewrap system 74 is operable to wrap the bale 56 with a wrap materialinside the baling chamber 54. Once the bale 56 is formed to a desiredsize, the wrap system 74 feeds a wrap material into the baling chamber54 to wrap the bale 56 and thereby secure the crop material in a tightpackage and maintain the desired shape of the bale 56. The wrap materialincludes, but is not limited to, a twine, a net mesh, or a solid plasticwrap. Movement of the gate 36 into the open position simultaneouslymoves the belts clear of the formed bale 56 and allows the formed andwrapped bale 56 to be discharged through the rearward end 38 of thebaling chamber 54.

Referring to FIG. 2, the housing 32 includes a first side wall 76positioned generally parallel with the first circular end face 58 of thebale 56 during formation of the bale 56 in the bale formation system 52.The housing 32 includes a second side wall 78 positioned generallyparallel with the second circular end face 60 of the bale 56 duringformation of the bale 56 in the bale formation system 52. It should beappreciated that the first circular end face 58 and the first side wall76 may be positioned on either the left side or the right side of theround baler 20, relative to the direction of travel 40 of the roundbaler 20 while gathering crop material, with the second circular endface 60 and the second side wall 78 positioned on the other of the leftside or the right side of the round baler 20, opposite the firstcircular end face 58 and the first side wall 76.

In some circumstances and/or for some baling operations, it is desirableto measure or otherwise determine a weight of the bale 56 afterformation and before being discharged from the interior region 34 of theround baler 20 and onto the ground surface 46. One process ofdetermining the weight of the bale 56 is to fully support the bale 56 onthe gate 36, and measure the force applied to one or more hydraulic gatecylinders 80 holding the gate 36 and the bale 56 in an intermediateposition. In order to do so, the bale 56 and the gate 36 are be moved tothe intermediate position, such that the weight of the bale 56 is fullysupported by the gate 36.

In the intermediate position, one or more pressure or force sensors (notshown) may sense data related to the forces acting on the hydrauliccylinders holding the gate 36 in the intermediate position. Knowingtheses forces and the weight and geometry of the gate 36, the weight ofthe bale 56 is accurately determined. In order to accurately make thisdetermination, however, the bale 56 should be consistently positionedrelative to the gate 36. In order to consistently position the bale 56on the gate 36 in the intermediate position, the rotation of the formingbelts 64 in the endless loop may need to be stopped so that the formingbelts 64 do not rotate the bale 56 when in the intermediate position.Additionally, tension in the forming belts 64 may need to be reduced,i.e., slack introduced into the forming belts 64, so that the formingbelts 64 do not discharge the bale 56 from the gate 36 when in theintermediate position.

Referring to FIG. 2, the take-up roller 68 is moveably attached toeither the gate 36 or the housing 32 in a suitable manner that allowsthe take-up roller 68 to move relative to the gate 36 and/or the housing32 as the gate 36 moves between the open position and the closedposition, so that the take-up roller 68 maintains tension and/or reducesslack in the forming belts 64 as the gate 36 moves from the closedposition into the open position. As used herein, the term “tension” isdefined as a force that tends to produce an elongation of a body orstructure. As used herein, the term “slack” is defined as looseness inthe forming belts 64, i.e., not taut. It should be appreciated thatincreasing tension of the forming belts 64 reduces slack in the formingbelts 64, whereas decreasing tension in the forming belts 64 introducesslack into the forming belts 64.

In one embodiment, the take-up roller 68 is attached to the gate 36 viaa take-up shaft 82 and an interconnecting roller lever 84. However, itshould be appreciated that the take-up roller 68 may be attached to thegate 36 or the housing 32 in some other manner not shown in the Figuresor described herein. The take-up shaft 82 extends between the first sidewall 76 and the second side wall 78 of the housing 32. The take-up shaft82 defines a shaft axis 86. The shaft axis 86 is a longitudinal centerof the take-up shaft 82, and generally extends perpendicular to thecentral longitudinal axis 44 of the round baler 20. The shaft axis 86 isgenerally parallel with the gate rotation axis 42. The take-up roller 68is attached to the take-up shaft 82, with the take-up roller 68rotatable with the take-up shaft 82 about the shaft axis 86, relative tothe gate 36 and/or the housing 32. In one embodiment, the take-up shaft82 is rotatably attached to the gate 36. However, in otherimplementations, the take-up shaft 82 may be rotatably attached to thehousing 32.

The roller lever 84 is attached to and rotatable with the take-up shaft82 about the shaft axis 86. The roller lever 84 interconnects thetake-up shaft 82 and the take-up roller 68. While only a single rollerlever 84 is described herein, it should be appreciated that the roundbaler 20 may include multiple roller levers 84 interconnecting thetake-up shaft 82 and the take-up roller 68. For example, in theimplementation shown in the Figures, a first roller lever 84A isdisposed adjacent the first side wall 76, and a second roller lever 84Bis disposed adjacent the second side wall 78 of the housing 32. A firstend 88 of the roller lever 84 is fixedly attached to the take-up shaft82. The take-up roller 68 is rotatably mounted to a second end 90 of theroller lever 84, such as with a bearing or other similar mounting. Theroller lever 84 positions the take-up roller 68 away from the shaft axis86 by a radial distance.

FIG. 4 illustrates a schematic block diagram of a control system 100configured to determine a component or systems malfunction or failure ofthe baler 20 using one or more temperature sensing radio frequencyidentification (RFID) tags 102 that identify heat generated by acomponent. The control system 100 includes one or more electroniccontrollers 104, also known as an electronic control unit (ECU), each ofwhich is connected to a controller area network (CAN) bus (not shown)and to the various devices, systems, parts, or components of the tractor10 and the baler 20. The CAN bus is configured to transmit electricsignals for the control of various devices connected to the bus as wellas to transmit status signals that identify the status of the connecteddevices.

The controller 104, in different embodiments, includes a computer,computer system, or other programmable devices. In these and otherembodiments, the controller 104 includes one or more processors 106(e.g. microprocessors), and an associated memory 108, which can beinternal to the processor or external to the processor. The memory 108includes, in different embodiments, random access memory (RAM) devicescomprising the memory storage of the controller 104, as well as anyother types of memory, e.g., cache memories, non-volatile or backupmemories, programmable memories, or flash memories, and read-onlymemories. In addition, the memory can include a memory storagephysically located elsewhere from the processing devices, and caninclude any cache memory in a processing device, as well as any storagecapacity used as a virtual memory, e.g., as stored on a mass storagedevice or another computer coupled to controller 104. The mass storagedevice can include a cache or other dataspace which can includedatabases. Memory storage, in other embodiments, is located in a cloudsystem 110, also known as the “cloud”, where the memory is located inthe cloud at a distant location from the machine to provide the storedinformation wirelessly to the controller 104 through the antenna 28operatively connected to a transceiver 111, which is operativelyconnected to the controller 104. When referring to the controller 104,the processor 106, and the memory 108, other types of controllers,processors, and memory are contemplated. Use of the cloud for storingdata leads to storage economies of scale at a centrally locatedoperation's center, where data from a large number of balers is stored.In other embodiments, data from other types of work machines is stored.

The controller 104 executes or otherwise relies upon computer softwareapplications, components, programs, objects, modules, or datastructures, etc. Software routines resident in the included memory 108of the controller 104, or other memory, are executed in response to thesignals received from the RFID sensors 102 which are located on, at orwithin the baler 20 as described herein. The controller 104 alsoreceives signals from other controllers such as an engine controller anda transmission controller. The controller 104, in other embodiments,also relies on one or more computer software applications, that arelocated in the “cloud” 110, where the cloud generally refers to anetwork storing data and/or computer software programs accessed throughthe internet. The executed software includes one or more specificapplications, components, programs, objects, modules or sequences ofinstructions typically referred to as “program code”. The program codeincludes one or more instructions located in memory and other storagedevices which execute the instructions which are resident in memory,which are responsive to other instructions generated by the system, orwhich are provided at a user interface operated by the user.

The tractor 10 and the baler 20 include a plurality of other types ofsensors, in addition to the RFID tag sensors 102, each of which indifferent embodiments, identifies machine device status and transmitssensor information to the controller 104. In one embodiment, differenttypes of machine operating systems 112 are configured to perform workmachine functions as would be understood by one skilled in the art. Theconditions and statuses of these machine operating systems 112 aretransmitted as signals to the controller 104 as is understood by oneskilled in the art.

An operator user interface 120 is operatively connected to thecontroller 104 and is located in the cab 26 to display machineinformation to an operator, located in the cab 26, as well as to enablethe operator to control operations of the tractor 10, the baler 20, orother work machines. The user interface 120 includes a display 122 todisplay status information directed to the condition or status of themachine 10 as well as the baler 20. Status information includes, but isnot limited to, the operating status of a machine operating system 112including various components, parts, or systems of the baler 20. Theuser interface 120 further includes operator controls 124 configured toenable the operator to control the various functions and features of themachine operating system 112. A component alert device 126 is located atthe user interface 120 and provides an alert function to an operator foralerting the operator in the event of a system, part, or component beingfound to be subject to a malfunction. As used herein, system, part,device, and component are used interchangeably when identifying a faultcondition with the RFID temperature sensor. The alert device 126includes, but is not limited to, a visual alert, a sound alert, or atransmitted alert to a remote receiver.

In one embodiment, electrical communication between the tractor 10 andthe baler 20 is through an electrical cable, not shown, disposed alongthe connection 33. In other embodiments, sensor information and machineoperating systems information is transmitted wirelessly between thetractor 10 and the baler 32.

Other work machines are known as autonomous machines are controlledremotely without operator intervention at the machine itself. In such asystem, a remote control system 130 is used to remotely controloperation of the machine 10 or baler 20 through web-based communicationtools and platforms with the cloud 110, as is understood by thoseskilled in the art. In one embodiment, an operator or manager is locatedat the remote control system 130, which due to its cloud communicationprotocol, is located remotely from the machine 10 and the baler 20. Insuch an embodiment, the control system 100 is a distributed controlsystem having components locate at one or more of the work machines, thecloud, and the remote control system.

In a remotely controlled machine in which the operator is not located atthe work machine, or in an operator controlled machine, the controlsystem 100 is configured to identify when a component or system of themachine being monitored has been damaged, through wear or throughbreakage. One or more of the temperature sensing RFID tags 102 areconfigured to sense temperature generated by moving parts of the machineand its components and to transmit the temperature to the controller104, either wirelessly or by wire. In different embodiments, the RFIDsensor identify only temperature. Temperature sensing can be achieved oncertain specialized RFID tags by analyzing the change in impedance ofthe circuit based on temperature. In other embodiments, the RFID sensorincludes a component identifier that identifies the component to whichthe sensor is attached as identifying the temperature of the identifiedcomponent.

In different embodiments, the sensors 102 are located at or within thebaler 20 to identify a temperature of the part, component, or device atwhich the sensor is located. For instance, as illustrated in FIG. 5, anRFID sensor 140 is coupled to a bearing 142. The RFID sensor 140 isattached by one or more couplers, such as by an adhesive, to a surface144 of the bearing 142. In one embodiment, the adhesive is relativelyrobust to insure that the sensor 140 does not become dislodged from itslocation during operation of the bearing. In other embodiments, thesensor 140 is mounted to a plate and the plate is coupled to the bearingby connectors. Other types of couplers are contemplated.

The bearing supports a shaft (not shown) in an aperture 146, such as ashaft supporting one of the rollers 66. In the embodiment of FIG. 5, thesensor 140 is located on a bearing ring 148 that rotates with respect toa bearing housing 150. As the bearing ring 148 rotates, an operatingtemperature is generated near or at the bearing ring 148. The sensor 140determines the temperature of the bearing ring 148. Thereceiver/transmitter 152 (see FIG. 4) interrogates the sensor 140, as isunderstood by one skilled in the art. In response to the interrogation,the receiver/transmitter 152 receives a temperature signal from thesensor 140, which is transmitted to the controller 104. In anotherembodiment, the sensor 140 is coupled to the bearing housing 150.

FIG. 6 illustrates a gearbox 154 covered by the housing 35 of FIG. 3. Atemperature sensing RFID sensor 156 is coupled to an exterior surface ofthe gearbox 154 to sense the temperature of the gearbox 154. While aparticular location of the sensor 156 is illustrated, other locations ofthe sensor 156 on the gearbox 156 are contemplated.

In different embodiments, RFID sensors are located at sensing locationsthat are considered to experience undesirable operating temperaturesduring operation of the baler. By locating, the sensor at locations ofpotential undesirable temperature change, the controller 104, under manyconditions, makes a determination of changes in sensed temperature. Forinstance, in one embodiment, the controller 104 determines a change insensed temperature from a non-operating temperature to an operatingtemperature. If the change is too great, then an alert is generated atthe component alert 126. In other embodiments, the sensed temperature iscompared to a threshold temperature that is stored in memory. Becausedifferent parts, component, devices, and systems generate differentvalues of temperature, a table of threshold temperature thresholdlocated in a stored lookup table are used to provide an alert.

FIG. 7 illustrates some of the parts, but not all of the parts of thebaler 20, at which the RFID sensors 140 are located in one or moreembodiments. In this illustration, certain parts are identified as beingcandidates for temperature monitoring due to the function of those partsas well as the likelihood of temperature changes occurring duringharvesting that could result in part or system damage. Other locationsof RFID sensor 140 within or at baler 20 are contemplated. While notshown in FIG. 7, one or more sensors 140 are located on a PTO driveline160, a crop pickup assembly 162, a crop feeding rotor 164, and thegearbox 154. In addition, one or more of the bale rollers 66 each havean associated RFID sensor 140 to identify the temperature of the rollerand/or a support mechanism, such as an associated bearing supporting theroller. In one embodiment bale roller sensors are located at bearingsupporting rotation of the bale roller. In other embodiments, the baleris a self-propelled machine and does not include a PTO driveline.

The receiver/transmitter 152 of FIG. 4, in different embodiments,includes an RFID reader that is either located at the baler 20, thetractor 10, or is remotely located from either the tractor 10 or thebaler 20. In one embodiment, as seen in FIG. 8, the receiver/transmitter152 is a hand-held reader 170. In another embodiment illustrated in FIG.8, the receiver/transmitter 152 is equipment dedicated reader 172. Eachof the readers 170 and 172 is configured to interrogate one or moresensors 140 and to transmit received sensor information to thecontroller 104. Each of the reader identifies two values, thetemperature of the associated component and an identity of the componentat which the RFID sensor is located. Since each of the RFID sensorsincludes a unique component identifier, the sensed temperature isassociated with a particular component. In this way, components thatexperience improper temperatures are identified. By using a multiplicityof network of RFID sensors 140 as part of the RFID sensor system, adetermination of machine health is determined and used to provide atemperature alert, i.e. a fault condition, to the operator or equipmentmanager. In one or more embodiments, the RFID sensors are located atcomponents most critical to uptime. In the case of the handheld reader170, the signal identifying temperature and identifiers is transmittedto the antenna 28 of FIG. 4. In one embodiment, each of the RFID sensorsprovides a temperature of an associated component, which is not a highenough temperature by itself to trigger a component alert. In thisembodiment, however, if a large number of components registers highvalues, a system alert is provided to the operator or user to make aninvestigation into the cause of the higher temperatures.

The controller 104 is configured to determine the operating status ofcomponents based the identified temperatures of the monitoredcomponents. Temperature data is processed with controller softwareapplied to make decisions about machine health based on differentprocedures. High temperatures, in one or more embodiments, are anindication of pending mechanical failure. The controller 104, indifferent embodiments is configured to identify fault conditions thatindicate potential mechanical malfunctions or failures in one or moreidentification schemes as follows:

-   -   1) Absolute threshold: a temperature at which dry crop matter        combusts (230 degrees F.) minus a safety factor;    -   2) Relative threshold: a temperature change compared to an        original ambient temperature and an operating temperature of the        monitored component;    -   3) Expected temperature: determined by location of mounting        (e.g. gearbox), where threshold is set based on a known out of        bounds temperature limit, i.e. a predetermined threshold        temperature, based on the type of component;    -   4) Comparative temperature: one location is measurably higher        than other similar locations (e.g. left vs. right);    -   5) Rate of change: an unexpected increase in temperature based        on operating mode over a predetermined period of time; and    -   6) Loss of signal: indicates a loss of sensor or failure of        component (e.g. pickup tine missing with attached sensor).

These and other identifications of a fault condition include, but arenot limited to: and absolute threshold, a relative threshold, anexpected temperature threshold, a comparative temperature, or a changein temperature over a period of time.

In another embodiment, the handheld RFID reader 170, a plurality of RFIDtags, and a software package to read and analyze data transmitted by theRFID tags are supplied as a kit that is provided to a manufacturer, atechnician, or an end user to be incorporated into a baler or other workmachine. The software package, in different embodiments, includes a userinterface such as that described with respect to FIG. 9. In one or morekits, a controller is not provided and the software package isconfigured to operate on a specific controller as needed by the enduser.

The controller 104 identifies potential mechanical failures andtransmits relevant information to the user interface where it isdisplayed on the display 122. FIG. 9 illustrates one embodiment of ascreen display 180 that is provided to the display 122. As seen in FIG.9, the screen display includes a plurality of sections, each of which isdedicated to a particular grouping of information. A first section 182includes an illustration of the baler 20 which identifies the status ofdifferent components, including bearings and the location of thebearings. Each of the bearing's locations is shown and a condition ofthe bearing is identified with a status based on color. For instance, afirst bearing 184 is identified with a first color, such as green, toindicate that the identified bearing is operating at a normal operatingtemperature. A second bearing 186 is identified with a second color,such as yellow, to indicate the identified bearing is operating outsidea normal temperature. A third bearing 188 is identified with thirdcolor, such as gray, to indicate that the RFID sensor is notcommunicating. Other colors or greyscale shades are contemplated as wellas icons of different types to indicate status.

A second section, the summary section 190, is dedicated to illustratingsummary information. In this section, at least one embodiment includesan identification of a diagnostic trouble code (DTC), an identificationof the type of failure, i.e. bearing failure stop machine, and a bearingpart number. Other DTC's, types of failure and part numbers arecontemplated. Section 190 in another embodiment illustrates a historicalpattern of the bearing temperatures.

A third section 192 is dedicated to illustrate system status includingstatus of a bale chamber 194, a feed system 196, and a net wrap system198. Each of these subsection identifies the status of parts location inthe identified system by part number, location; i.e. left (L) or right(R), and a status of the left or right part by a color code. Forinstance, the arrow 200 points to an “R” identified by the color red toindicate an imminent failure which requires the machine operation to bestopped. The arrow 202 points to an “R” identified by the color yellowthat indicates that the identified part should be investigated soon andrepaired or replaced as necessary.

As described herein, the detection system identifies operatingconditions that lead to component malfunctions or failure using RFIDtags that are customized to include part numbers identifying thelocation of the RFID tags. Since the RFID tags are a passive, devicesthe cost of such tags is relatively inexpensive that leads to a largenumber of tags being used as needed. In one embodiment, the RFID tagsinclude a longer antenna, than typically seen RFID applications such asused in a commercial setting. The longer antenna also provides forwrapping the RFID tag around a part, such as a bearing, to improvereception. Since there are over 100 possible bearing locations on baler,the low cost of RFID tags provides for an improved assessment of baleroperations.

Alternate embodiments of the control system include the RFID sensorbeing located at a variety of different locations. For instance, indifferent embodiments, the RFID sensor is mounted directly to the workmachine. Such work machines include, but are not limited to a harvestingunit such as the baler towed behind a tractor described herein, or aself-propelled work machine. In another embodiment, the hand-held ormobile reader includes the use of an RFID interrogator held or operatedby a technician or an operator, but not mounted directly on the workmachine. For instance, the technician could use the reader as part of aregularly scheduled maintenance check to determine if a component, suchas a bearing, has been damaged or has failed during use. In oneembodiment, the hand-held reader includes a cell phone or mobiletelephone having an application (app) configured to identify machinefailure or malfunction. A dedicated hand-held device is alsocontemplated. In a further embodiment, the RFID reader is mounted on atractor in which the RFID reader is directed toward the work machine.

Due to the low cost of the RFID sensors, redundancy is used in differentembodiments, to improve the accuracy and reliability of the sensingsystem. Redundant sensors are also used to diagnose a sensor failurewhen there is a data mismatch. In addition, the machine health data notonly is used real time to alert the operator at the point of use, but isstored, in some embodiments, for historical reasons and shared to thecloud for remote fleet management.

While embodiments incorporating the principles of the present disclosurehave been disclosed hereinabove, the present disclosure is not limitedto the disclosed embodiments. Consequently, this application is intendedto cover any variations, uses, or adaptations of the disclosure usingits general principles. Further, this application is intended to coversuch departures from the present disclosure as come within known orcustomary practice in the art to which this disclosure pertains andwhich fall within the limits of the appended claims.

The invention claimed is:
 1. A method of detecting a fault condition inone or more balers, each of which includes a crop feed system and a balechamber, wherein each of the one or more balers is configured to balecut crop, the method comprising: identifying at least one location inthe one or more balers, wherein the at least one identified locationgenerates heat during an operation of a component of the baler; placinga radio frequency identification (RFID) tag at the at least oneidentified location, wherein the RFID tag includes a temperature sensingfeature; receiving transmitted data from the RFID tag; identifying, fromthe received data, a temperature value of the at least one identifiedlocation; and providing an indictor based on the identified temperaturevalue.
 2. The method of claim 1 wherein the receiving the transmitteddata includes receiving transmitted data having a first component and asecond component, wherein the first component includes a locationidentifier and the second component includes the temperature value. 3.The method of claim 2, wherein the location identifier includes anidentifier identifying the component identified by location.
 4. Themethod of claim 2 further comprising comparing the temperature value toa threshold value.
 5. The method of claim 4 wherein the providing anindicator further comprises providing an indicator if the comparison ofthe temperature value to the threshold value indicates an occurrence ofa fault condition at the at least one location.
 6. The method of claim 5wherein the threshold value is one of a predetermined temperaturethreshold value or an ambient temperature value.
 7. The method of claim1 wherein the providing an indicator further comprises providing analert, wherein the alert is one of a visual alert, a sound alert, or atransmitted alert to a remote receiver.
 8. The method of claim 1 furthercomprising placing a second RFID tag at or near the at least onelocation, wherein the second RFID tag includes a temperature sensingfeature.
 9. The method of claim 8 further comprising receiving seconddata from the second RFID tag and comparing the second data from thesecond RFID tag to the data from the first mentioned RFID tag todetermine a fault condition related to one or both of the firstmentioned RFID tag and the second RFID tag.
 10. The method of claim 1wherein the identifying at least one location further comprisesidentifying at least one moving component in a plurality of the one ormore balers wherein the at least one moving component is located in thecrop feed system or the bale chamber, in each of a plurality of balers.11. The method of claim 10 wherein the placing an RFID tag includesplacing an RFID tag at or near the at least one moving component in eachof the plurality of balers.
 12. A system for identifying a faultcondition in one or more balers, each of which includes a plurality ofcomponents, the system comprising: one or more RFID tags, wherein eachof the one or more RFID tags includes a temperature sensor and a couplerto connect each one of the one or more RFID tags to a location at, near,or on one of the plurality of components; a receiver configured toreceive temperature information from each of the one or more RFID tags;a user interface; a controller operatively connected to the receiver andto the user interface, the controller including a processor and amemory, wherein the memory is configured to store program instructionsand the processor is configured to execute the stored programinstructions to: receive temperature information from the receiver;identify a fault condition of one or more of the plurality of componentsbased on the received temperature information; and display an indicatorat the user interface based on the identified fault condition.
 13. Thesystem of claim 12 wherein the identify a fault condition includescomparing the received temperature information to a predeterminedtemperature.
 14. The system of claim 13 wherein the predeterminedtemperature is one of an absolute threshold, a relative threshold, anexpected temperature, a comparative temperature, or a change intemperature over a period of time.
 15. The system of claim 12 whereinthe system comprises one of a self-propelled bailer or a towed baler.16. The system of claim 12 wherein the system comprises a kit configuredto be located on one of a self-propelled baler or a towed baler.
 17. Abaler configured to bale cut crop, the baler comprising: a crop feedsystem and a bale chamber; one or more RFID tags, each of which includesa temperature sensing feature, wherein each of the one or more RFID tagsis located on, at, or near a component of the baler; an RFID tag readerconfigured to receive temperature information from the one or more RFIDtags; a user interface including one or more indicators; a controlleroperatively connected to the user interface and to the RFID tag reader,the controller including a processor and a memory, wherein the memory isconfigured to store program instructions and the processor is configuredto execute the stored program instructions to: receive the temperatureinformation from the RFID tag reader; identify a fault condition of oneor more of the plurality of components based on the received temperatureinformation; and activate one of the one or more indicators at the userinterface based on the identified fault condition.
 18. The baler ofclaim 17 wherein the identify a fault condition includes comparing thereceived temperature information to a predetermined temperature.
 19. Thebaler of claim 18 wherein the predetermined temperature is one of anabsolute threshold, a relative threshold, an expected temperature, acomparative temperature, or a change in temperature over a period oftime.
 20. The baler of claim 19 wherein the identify a fault conditionof one or more of the plurality of components is an absence of thereceipt of temperature information from one or more of the RFID tags.